* * * FOR ALL PIP 2
TASK 72-00-02-430-820
1 . General.
A.This procedure gives instructions to continue with the assembly of the propulsor module assembly (propulsor assembly). This procedure installs the high pressure turbine (HPT) module on the high pressure compressor (HPC) module. The HPT module buildup includes the turbine center frame (TCF) (35-015C) (SIN 92500), HPT rotor assembly (34-021) (SIN 15000), HPT stage 2 nozzle (stage 2 nozzle) (34-012) (SIN 17400), and combustor diffuser nozzle assembly (CDN assembly) (33-021) (SIN 0010A) or (33-021B) (SIN 0010A).
•
Propulsor assembly (30-021 , 72-00-00) (SIN 0010C) (SB 72-0161) (Propulsor Module - PIP2 Configuration)
•
Propulsor assembly (30-022 , 72-00-00) (SIN 0010C) (SB 72-0161) (Propulsor Module - PIP2 Configuration)
•
Propulsor assembly (30-023 , 72-00-00) (SIN 0010C) (SB 79-0018).
CAUTION:
DO NOT MOVE THE ASSEMBLY STAND, 11C4377, WITH ENGINE PARTS INSTALLED. INJURY TO PERSONNEL OR DAMAGE TO ENGINE HARDWARE CAN OCCUR.
B.This procedure starts with the propulsor assembly in the vertical position on the 9481M84   assembly stand or 11C4582   core module build-up fixture at the equivalent build status of TASK 72-00-02-430-821 (72-00-02, ASSEMBLY 001, CONFIG 02) . Refer to Figure 1001.
C.Make sure that there is no foreign material in the assemblies and modules of the propulsor assembly.
D.Do an inspection of the HPT rotor assembly (34-021) (SIN 15000) forward flange and the CDN assembly (33-021) (SIN 0010A) or (33-021B) (SIN 0010A) aft flange for foreign material. Refer to TASK 72-00-02-200-801 (72-00-02, INSPECTION 001) .
E.Make sure that the mating parts are serviceable and have no deterioration.
F.Make sure to see the L mark on the inside diameter of the HPT rotor. If not, use a C05-003  pen to add the L mark on the inside diameter of the HPT rotor (34-021) (SIN 15000). Refer to Figure 1003.
G.Make sure that the HPT rotor parts are in the correct position.
H.Do an inspection of the parts for physical damage.
I.Make sure that all the bolts (02-010 , 72-53-00) (SIN 15020) and (02-020 , 72-53-00) (SIN 15021) are installed on the HPT rotor assembly forward flange and do not have thread damage.
J.Make sure that the spline drive self-locking nuts (nuts) (34-260) (SIN 15040) that will be used were not part of an engine that was operated.
K.Read this procedure and know the instructions and special tools before the installation of the assemblies and modules of the propulsor assembly.
L.Install all bolts with the heads up or forward, unless specified differently.
M.Clock positions are aft-looking-forward (ALF), unless specified differently.
N.Make sure that the mating flanges are clean and free from damage as follows:
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THESE PRODUCTS.
(1)Make sure that the forward flanges of the CDN assembly (33-021) (SIN 0010A) or (33-021B) (SIN 0010A) and the HPT rotor assembly (34-021) (SIN 15000) are clean and without nicks or lifted metal. If not, clean the flanges with C04-002  Stoddard solvent, C04-003  acetone, or C04-035  isopropyl alcohol.
(2)Make sure that the aft mateface of the CDP seal (02-460 , 72-31-00) (SIN 050NC) and the HPC aft extension case (extension case) (10-080 , 72-30-00) (SIN 080AL) aft flanges are clean and free from nicks or lifted metal. If not, clean the flanges with C04-002  Stoddard solvent, C04-035  isopropyl alcohol, or a 50-50 blend of C04-035  isopropyl alcohol and C04-228  denatured alcohol to clean the aft mateface surface of the CDP seal (02-460 , 72-31-00) (SIN 050NC).
O.This assembly contains shafts that are very important. Critical areas of the shafts that require caution and a visual inspection during the assembly procedure, are identified throughout this procedure. Refer to Figure 1002.
P.Make sure that the condition of the stationary CDP seal honeycomb (01-168 , 72-41-00) (SIN 08001) as either previous engine run or pre-grooved according to TASK 72-41-20-300-811 (72-41-20, REPAIR 010) before the HPT module build-up is installed onto an engine run rotating CDP seal (01-460 , 72-31-00) (SIN 050NC). Rotating CDP seal teeth must be restored to piece part serviceability in order to properly break in new stationary CDP seal honeycomb.
2 . Tools, Equipment, and Materials.
NOTE:
You can use equivalent alternatives for tools, equipment, and consumable materials.
A.Tools and Equipment.
(1)Special Tools.
 
Tool No.
Description
 
11C3018G03
Fixture, Support - HPT Rotor, Vertical (vertical support fixture)
 
11C3025G04
Strongback, Lift and Turn - Super Core (strongback)
 
11C3039G02
Bracket Set, FWD Propulsor, Ground Handling and Shipping (bracket set)
 
11C3044G01
Adapter Assembly, Overhead Support - Engine Modules (engine module adapter assembly)
 
11C3046G01
Kit, Camera - HPC/HPT Hole Alignment (camera kit)
 
11C3047G01
Bracket, Lift/Turn - Frame, Fan Hub (lift/turn bracket)
 
11C3053G01
Adapter, Torque - Install/Remove No. 3 Bearing Locknut (torque adapter)
 
11C3055G03
Rotor Lock - Aft, HPT Rotor (rotor lock)
 
11C3057G02
Fixture, Lift/Turn - FHF (fan frame lift/turn fixture)
 
11C3067G01
Fixture, Retainer - No. 4 Bearing Inner Race/Oil Scoop/Rotating Seal/Forward Seal (retainer fixture)
 
11C3133G01
Fixture, Lock - HPC Rotor (lock fixture)
 
11C3147G02
Fixture, Runout - CDP Seal/HPT Rotor (runout fixture)
 
11C3157G01
Tool Set, Install/Remove - Air Duct, HPT (air duct install/remove tool)
 
11C3197G01
Bracket Set, FHF (bracket set)
 
11C3266G02
Fixture, Installation HPT Air Duct/HPT Rotor Disk (air duct installation fixture)
 
11C3266G03
Fixture, Installation HPT Air Duct/HPT Rotor Disk (air duct installation fixture)
 
NOTE:
Tool 11C3266G03 is an alternative to 11C3266G02.
 
11C3281G02
Bracket Set, Support - Main Engine, FHF (pedestals)
 
11C3281G03
Bracket Set, Support - Main Engine, TCF (pedestals)
 
11C3387G01
Guide Tube, Borescope - HPT/HPC Rotor Joint (borescope guide)
 
11C4480G01
Bracket Set, FHF Aft Flange (FHF brackets)
 
NOTE:
Tool 11C4480 is alternative to 11C3057.
 
11C4504G02
Fixture, Lift - HPC, FHF and Booster (lift fixture)
 
11C4525G01
Deleted
 
11C4582G01
Fixture, Build-Up - Core Module (core module build-up fixture)
 
NOTE:
Tool 11C4582 is alternative to 9481M84.
 
11C4623G01
Fixture, Clamp - Stage 10 OGV Sealing Ring (restraining ring)
 
11C4699G01
Fixture, Build Up - Core Module (assembly fixture)
NOTE:
Tool 11C4699 is alternative to 11C4582 and 9481M84.
NOTE:
Tool 11C4699 was developed as a hinged stand to be used when the hoist hook height is restricted.
 
11C4822G01
Fixture, Storage - Vertical Core
NOTE:
Tool 11C4822G01 is an alternative to 11C4582 and used to store engine cores without the fan booster installed.
NOTE:
Tool 11C4822G01 was developed for storage purpose only. Do not use it for assembly.
 
11C4822G02
Fixture, Storage - Vertical Core
NOTE:
Tool 11C4822G02 is an alternative to 11C4582.
NOTE:
Tool 11C4822G02 was developed for storage purpose only. Do not use it for assembly.
 
11C4888P01
Fixture, Torque - CDP Seal Joint (torque wrench)
 
7C2015G01
Fixture, Lift and Turn - Propulsor Aft (lift/turn fixture)
 
7C2127G01
Inspection System - Core Rotor Assembly, Portable (inspection system)
 
9429M25G01
Plate Torque Adapter - Install/Remove (torque adapter plate)
 
9429M43G01
Adapter, Overhead Support - Fan Hub Frame (fan frame overhead adapter)
 
9429M45G01
Adapter, Overhead Support-K Flange (K-flange overhead adapter)
 
9429M46G01
Adapter Assembly, Overhead Support - TCF (TCF overhead adapter)
 
9429M48G01
Adapter, Overhead Support - Bridge Beam (bridge beam adapter)
 
9481M84G01
Stand, Assembly - Super Core (assembly stand)
 
9C1276G01
Protector, Compressor Rotor - Stage 8-10 Bore (bore protector)
(2)Standard Tools and Equipment.
 
Description
Manufacturer
 
Borescope Kit
Local Purchase
 
Customer Overhead Rail System
Locally Used
 
Extension Adapter - GAX24 (extension adapter)
Snap-On Tools Corp. 8049 28th Street Kenosha, WI 53140
 
Sweeney No. 8100 Torque Multiplier (torque multiplier)
B.K. Sweeney Company 6300 Stapleton South Drive Denver, CO 80216
 
Three Point Vertical Multi Leg Sling with a capacity of at least 5000 lb (2268 kg), and a minimum sling length of 36.00 inches (914.4 mm) to be used with 11C4505
Local Purchase
(3)Locally Manufactured Tools. None.
B.Consumable Materials.
 
Code No.
Description
 
C02-008
Deleted
 
C02-019
Oil, Engine Lubricating (engine oil)
 
C02-023
Oil, Engine Lubricating (engine oil)
 
C02-058
Compound, Thread Lubricating (graphite)
 
C04-002
Solvent, Stoddard
 
C04-003
Solvent, General (acetone)
 
C04-228
Alcohol, Ethyl, Anhydrous, Denatured (denatured alcohol)
 
C04-035
Isopropyl Alcohol
 
C05-003
Marking Pen (pen)
 
C10-109
Utility Wax (wax)
 
C10-182
Cloth, Cleaning for Aircraft Structural (SAE-AMS 3819, BMS 15-5) (cloth)
C.Referenced Procedures.
 
ATA No.
Description
 
72-00-02
Assembly 001
 
72-00-02
Assembly 003
 
72-00-02
Inspection 001
 
72-00-53
Inspection 001
 
72-50-00
Assembly 001
 
72-50-00
Disassembly 001
D.Expendable Parts.
 
CSN
Description
 
(33-080)
Self-Locking Nut
 
(34-260)
Spline Drive Self-Locking Nut (nuts)
* * * FOR ALL PIP 2
Figure 1001   Installation of the Fan Hub Module on the Assembly Stand, 9481M84
* * * FOR ALL PIP 2
Figure 1001A   Installation of the Fan Hub Module in The Core Module Build-Up Fixture, 11C4582
* * * FOR ALL PIP 2
Figure 1002   Critical Shaft Areas within HPT Module
* * * FOR ALL PIP 2
Figure 1003   HPT Rotor Forward Bolt Location
3 . Procedure.
Subtask 72-00-02-430-871
A.Install the 11C3055   rotor lock on the aft end of the TCF assembly (15-130 , 72-54-00) (SIN 925A0) or (15-131 , 72-54-00) (SIN 925A0). Refer to TASK 72-50-00-430-801 (72-50-00, ASSEMBLY 001).
WARNING:
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR KILL YOU.
(1)Use a three-point vertical multi-leg sling and hooks with a minimum of 5000 lb (2268 kg) rated load and a minimum of 36.00 inches (914.4 mm) leg length to lift the 11C4504   lift fixture and put it above the extension case (10-080 , 72-30-00) (SIN 080AL). Refer to Figure 1004 and do as follows:
(a)Turn the quick turn handle (item 8) to make sure that the centering plate (item 3) is fully retracted.
(b)Remove the 24 flange screws (item 15) and plain nuts (item 14) from the 11C4504   lift fixture.
(c)Put the 11C4504   lift fixture on the plate of the support (item 19) that is installed on the HPC extension case flange.
(d)Align the hole pattern on the 11C4504   lift fixture and the extension case flange at the 12:00 o'clock position.
(e)Install the 24 flange screws (item 15) and plain nuts (item 14) on the extension case to secure the 11C4504   lift fixture, but do not tighten them.
(f)Tighten the 24 flange screws (item 15) and plain nuts (item 14) at the 12:00 o'clock position on the extension case.
(g)Tighten the 24 flange screws (item 15) and plain nuts (item 14) at the 06:00 o'clock position on the extension case.
CAUTION:
UNEVEN TIGHTENING OF HARDWARE CAN RESULT IN DAMAGE TO EQUIPMENT AND/OR TOOL FAILURE.
(h)Tighten the remaining flange screws (item 15) and plain nuts (item 14) in a criss-cross pattern.
(i)Turn the bearing collar locknut (item 9) one-half turn CCW to let the centering plate (item 3) float.
(j)Use the quick turn handle (item 8) to vertically adjust the centering plate (item 3) until the plate face enters the inner diameter and gets installed into the CDP seal.
NOTE:
The plate face is the area of the centering plate (item 3) with a reduced diameter.
NOTE:
The installation of the centering plate (item 3) in the CDP seal will center the 11C4504   lift fixture into the extension case.
CAUTION:
DO NOT OVER TIGHTEN THE BEARING COLLAR LOCKNUT (ITEM 9). OVER TIGHTENING CAN CAUSE DAMAGE TO EQUIPMENT.
(k)Turn the bearing collar locknut (item 9) CW against the washer (item 18) and lifter plate (item 6) to make sure that the hardware does not move.
(l)Use the internal shackle (item 10) to lift the engine hardware assembly without the gearbox and the external shackle (item 10) to lift the engine hardware with the gearbox.
NOTE:
The support CG (item 4) consists of a two position lifting point.
WARNING:
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR KILL YOU.
(m)Use a three-point vertical multi-leg sling to carefully lift and move the assembly to the necessary location.
(2)Remove the 11C4504   lift fixture from the extension case.
* * * FOR ALL PIP 2
Figure 1004   Installation of the Lift Fixture, 11C4504, on the Extension Case
Subtask 72-00-02-430-872
B.Install the 11C3025   strongback on the aft end of the TCF assembly (15-130 , 72-54-00) (SIN 925A0) or (15-131 , 72-54-00) (SIN 925A0). Refer to TASK 72-50-00-430-801 (72-50-00, ASSEMBLY 001). The 7C2015   lift/turn fixture is attached to the 11C3025   strongback to lift the HPT module buildup.
Subtask 72-00-02-220-102
C.Measure from aft face of the CDP seal (02-460 , 72-31-00) (SIN 050NC) to the HPC aft flange at four equally spaced locations. Record as CDPAVG. Refer to Figure 1005.
NOTE:
Before the HPT module build-up is installed, make sure that the condition of the stationary CDP seal honeycomb (01-168 , 72-41-00) (SIN 08001) and the rotating CDP seal (01-460 , 72-31-00) (SIN 050NC). Do not install new honeycomb without pre-groove per TASK 72-41-20-300-811 (72-41-20, REPAIR 010) or properly restored rotating CDP seal teeth, refer to TASK 72-31-46-300-801 (72-31-46, REPAIR 001). Refer to TASK 72-00-02-430-820 (paragraph 1.P.).
NOTE:
If the 11C3010   build-up fixture or 11C4275   build-up fixture is used for the HPT module there is no requirement to do the calculation of the HPTRPOS. This calculation is only required when positioning the HPTR/CDN/S2N clearance without the build stand.
* * * FOR ALL PIP 2
Figure 1005   Measurement of CDPAVG from the CDP Seal AFT Face to HPC AFT Flange
Subtask 72-00-02-220-103
D.Measure and calculate the dimension from the forward flange of the CDN assembly (33-021) (SIN 0010A) or (33-021B) (SIN 0010A) to the forward face on the HPT module buildup. Refer to Figure 1006.
WARNING:
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR KILL YOU.
(1)Lift the HPT module buildup with the 7C2015   lift/turn fixture attached to the 11C3025   strongback.
(2)Measure from the forward flange of the CDN assembly to the forward face of the HPT rotor disk in four equally spaced locations.
(3)Calculate the average dimension for HPTRBU.
Subtask 72-00-02-430-873
E.Calculate the HPT rotor forward position (HPTRPOS) as follows:
(1)CDPAVG minus HPTRBU = HPTRPOS
(2)The HPTRPOS measurement must be 0.060-0.080 inch (1.52-2.03 mm).
(3)Record the HPT rotor forward position as HPTRPOS.
Subtask 72-00-02-431-055
NOTE:
If the 11C3010   build-up fixture or 11C4275   build-up fixture is used for the HPT module there is no requirement to do the calculation HPTRPOS.
(4)Alternative Procedure Available. Install the HPT module on the CDN. Refer to TASK 72-50-00-430-801 (72-50-00, ASSEMBLY 001) (paragraph 3.Q.) and (paragraph 3.G.). If the combustion case is assembled to HPC extension case do the HPTRPOS calculation as follows:
(a)Measure the CDNAVG from the aft face of the rotating seal (02-460 , 72-31-00) (SIN 050NC) to the aft flange surface of the combustor on the propulsor. Refer to Figure 1007.
1Measure from the aft face of the rotating seal (02-460 , 72-31-00) (SIN 050NC) to the aft flange surface of the combustor at four equally-spaced locations.
2Calculate the average dimension for CDNAVG.
3Record as CDNAVG.
(b)Measure the HPTMBU dimension from the forward flange surface of the HPT case (01-490 , 72-52-00) (SIN 174B0) to the forward face of the stage 1 HPT rotor disk (02-280 , 72-53-00) (SIN 150A1) on the HPT module buildup. Refer to Figure 1008 and as follows:
WARNING:
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR KILL YOU.
1Lift up the HPT module buildup with the 7C2015   lift/turn fixture attached to the 11C3025   strongback.
2Measure from the forward flange surface of the HPT case to the forward face of the stage 1 HPT rotor disk in four equally-spaced locations.
3Calculate the average dimension for HPTMBU.
4Record as HPTMBU.
(c)Calculate the HPT rotor forward position (HPTRPOS) as follows:
1HPTMBU minus CDNAVG = HPTRPOS
2The HPTRPOS must be 0.060-0.080 inch (1.52-2.03 mm).
3Record the HPT rotor forward position as HPTRPOS.
* * * FOR ALL PIP 2
Figure 1006   Measurement of HPTRBU from CDN Assembly Forward Flange to HPT Rotor Disk Forward Face
* * * FOR ALL PIP 2
Figure 1007   Measurement of CDNAVG from Aft Face of the Rotating Seal to the Aft Flange Surface of the Combustor Stage 1 HPT Rotor Disk
* * * FOR ALL PIP 2
Figure 1008   Measurement of Dimension HPTMBU from the Forward Flange Surface of the HPT Case on the HPT Module Buildup
Subtask 72-00-02-640-048
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
CAUTION:
TOO MUCH LUBRICANT CAN DAMAGE ENGINE PARTS. REMOVE ANY UNWANTED LUBRICANT.
F.Lubricate the bolts (02-010 , 72-53-00) (SIN 15020) and (02-020 , 72-53-00) (SIN 15021) threads with C02-058  graphite. Make sure that the V-groove on the bolt threads has lubricant applied. Remove unwanted lubricant. No lubricant is permitted on the face of the HPT rotor disk.
Subtask 72-00-02-430-874
G.Make sure that the 11C3133   lock fixture is installed on the transfer gearbox (TGB) (01-010 , 72-25-00) (SIN 03200). Refer to TASK 72-00-02-430-821 (72-00-02, ASSEMBLY 001, CONFIG 02) for installation of the 11C3133   lock fixture.
Subtask 72-00-02-430-875
H.Make sure that the HPT rotor air duct (air duct) (34-310) (SIN 05002) is installed in the propulsor assembly. If not, refer to TASK 72-00-02-430-821 (72-00-02, ASSEMBLY 001, CONFIG 02) for the installation of the air duct.
* * * FOR ALL PIP 2
Figure 1009   (Sheet 1 ) Installation of the Camera Kit, 11C3046, in the HPT Rotor Assembly
* * * FOR ALL PIP 2
Figure 1009   (Sheet 2 ) Installation of 11C3387 Borescope Guide in the HPT Rotor Assembly
Subtask 72-00-02-430-876
I.Put the HPT module buildup, HPT rotor assembly (34-021) (SIN 15000) forward flange in dry ice as follows:
(1)Alternative Procedure Available. Put the ice dam (item 5) of the 11C3018   vertical support fixture in the position to hold dry ice. Refer to Figure 1010.
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
(a)Put dry ice in the ice dam (item 5) of the 11C3018   vertical support fixture.
WARNING:
BALANCE THE PARTS TO BE LIFTED BEFORE YOU OPERATE THE EQUIPMENT. DO NOT STAY BELOW THE EQUIPMENT WHEN YOU LIFT THE PART. DO NOT LIFT MORE THAN THE SPECIFIED WEIGHT. IF THE PARTS ACCIDENTALLY MOVE OR FALL, A BAD INJURY CAN OCCUR.
(b)Lift the HPT module buildup and lower the HPT rotor assembly forward rotor seal (seal) (02-250 , 72-53-00) (SIN 150A3) on the support ring (item 3) of the 11C3018   vertical support fixture.
(c)Leave the HPT rotor assembly forward flange in the dry ice for 30 minutes.
(d)Lift the HPT module buildup from 11C3018 vertical support fixture and dry ice.
Subtask 72-00-02-430-877
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
(1).A.Alternative Procedure. Put the ice dam (item 5) of the 11C3018   vertical support fixture in the position to hold liquid nitrogen. Refer to Figure 1010.
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
WARNING:
NITROGEN CAN DISPLACE OXYGEN IN ENCLOSED AREAS. USE IN A WELL-VENTILATED AREA.
(a)Put liquid nitrogen in the ice dam (item 5) of the 11C3018   vertical support fixture.
WARNING:
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR KILL YOU.
(b)Lift the HPT module buildup and lower the seal (02-250 , 72-53-00) (SIN 150A3) on the support ring (item 3) of the 11C3018   vertical support fixture.
(c)Leave the HPT rotor assembly forward flange in the liquid nitrogen until the liquid nitrogen is evaporated.
(d)Lift the HPT module buildup from the 11C3018   vertical support fixture and liquid nitrogen.
Subtask 72-00-02-430-878
CAUTION:
THIS ASSEMBLY IS A CRITICAL PROCEDURE. PROPER USE OF PROTECTIVE TOOLING AND POST ASSEMBLY INSPECTIONS MUST BE COMPLETED. REFER TO THE REQUIREMENTS OF THE ENGINE MANUAL TO MAKE SURE THAT NO DAMAGE HAS BEEN CAUSED BY THE ASSEMBLY PROCEDURE OR TOOLING.
J.Alternative Procedure Available. Prepare the 11C3046   camera kit in the HPT rotor assembly (34-021) (SIN 15000). Refer to Figure 1009 and do as follows:
(1)Put the 11C3046   camera kit on the aft end of the HPT rotor assembly as follows:
(a)Put the support sleeve (item 2) on the aft end of the HPT rotor assembly. The tabs on the support sleeve (item 2) will fit in the castellated ridge of the HPT rotor assembly.
Subtask 72-00-02-430-879
(2)Install the 11C3046   camera kit as follows:
(a)Put the cable assembly through the threaded tube of the 11C3055   rotor lock.
(b)Attach the main cable (item 17) to the receptacle (item 16).
(c)Attach the main cable (item 18) to the receptacle (item 16).
(d)Put the main cable (item 17) through the guide tube (item 3).
(e)Attach the camera (item 10) to the lock ring (item 7) with the stop ring (item 4) and capscrews (item 19).
(f)Attach the camera (item 10) and lock ring (item 7) assembly to the guide tube (item 3).
(g)Attach the main cable (item 18) to the controller (item 13).
(h)Set the video monitor (item 8) switch to operate on 110 VAC or 220 VAC 50/60 Hz electrical power.
(i)Connect the video monitor (item 8) to the electrical power source.
Subtask 72-00-02-430-880
J.A.Alternative Procedure. Install the 11C3387   borescope guide in the HPT rotor assembly (34-021) (SIN 15000). Refer to Figure 1009 and do as follows:
(1)Put the 11C3387   borescope guide on the 11C3055   rotor lock and secure with adapter pins.
(2)Install the borescope in the guide rod (item 3) of the 11C3387   borescope guide.
(3)Loosen two hand knobs (item 9) and use lever handle (item 10) to turn the guide rod (item 3).
Subtask 72-00-02-430-970
K.Remove the 11C4623   restraining ring from the forward end of the CDN assembly (33-021) (SIN 0010A) or (33-021B) (SIN 0010A).
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
(1)Make sure that the piston rings (01-225 , 72-41-00) (SIN 122A1) and (01-220 , 72-41-00) (SIN 122A0) are secured in the seal channel with C10-109  wax.
* * * FOR ALL PIP 2
Figure 1010   HPT Module Buildup in the Vertical Support Fixture, 11C3018, Dry Ice Dam
Subtask 72-00-02-430-881
CAUTION:
THIS ASSEMBLY IS A CRITICAL PROCEDURE. PROPER USE OF PROTECTIVE TOOLING AND POST ASSEMBLY INSPECTIONS MUST BE COMPLETED. REFER TO THE REQUIREMENTS OF THE ENGINE MANUAL TO MAKE SURE THAT NO DAMAGE HAS BEEN CAUSED BY THE ASSEMBLY PROCEDURE OR TOOLING.
L.Install the HPT module buildup onto the propulsor assembly. Refer to Figure 1011 and do as follows:
(1)Make sure that the TVCL offset holes are marked on the CDN assembly (33-021) (SIN 0010A) or (33-021B) (SIN 0010A) forward flange. If not, put a mark on the TVCL offset holes on the CDN assembly forward flange with a C05-003  pen.
WARNING:
BALANCE THE PARTS TO BE LIFTED BEFORE YOU OPERATE THE EQUIPMENT. DO NOT STAY BELOW THE EQUIPMENT WHEN YOU LIFT THE PART. DO NOT LIFT MORE THAN THE SPECIFIED WEIGHT. IF THE PARTS ACCIDENTALLY MOVE OR FALL, A BAD INJURY CAN OCCUR.
CAUTION:
THE HONEYCOMB IN THE PROPULSOR CAN BE DAMAGED, IF THE HPT ROTOR RADIAL SEALS ARE NOT INSTALLED IN THE CORRECT POSITION IN THE HONEYCOMB.
(2)Align the TVCL marks and slowly lower the HPT module buildup onto the propulsor assembly. Make sure that the HPT rotor radial seals engage in the correct position in the honeycomb of the propulsor assembly.
(3)Make sure that the letter “T” is marked on the CDN forward flange and on the HPC aft flange with a C05-003   pen.
(4)Make sure that the air duct (34-310) (SIN 05002) is installed.
(5)Use the 11C3046   camera kit or borescope with the 11C3387   borescope guide to align the L mark on the stage 1 HPT rotor disk (HPT rotor disk) (02-280 , 72-53-00) (SIN 150A1) with the H mark on the HPC rotor (15-012 , 72-30-00) (SIN 05000).
(6)Lower the HPT module buildup onto the propulsor assembly until there is only a small gap between the HPC flange on the propulsor and the bolts (02-010 , 72-53-00) (SIN 15020) and (02-020 , 72-53-00) (SIN 15021).
(7)Carefully turn the HPT rotor assembly (34-021) (SIN 15000) to let the bolts (02-010 , 72-53-00) (SIN 15020) and (02-020 , 72-53-00) (SIN 15021) drop into the flange boltholes.
(8)Lower the HPT module buildup until it seats on the propulsor assembly.
(9)Use the 11C3046   camera kit or borescope with the 11C3387   borescope guide to view the inside diameter of the flanges as follows:
(a)Make sure that the flanges touch each other and there are no gaps.
CAUTION:
MAKE SURE THAT THE HIGH RUNOUT AND THE LOW RUNOUT MARKS ARE ALIGNED FOR CORRECT ENGINE BALANCE. DAMAGE TO THE ENGINE CAN OCCUR.
(b)Make sure that the high runout (H) and the low runout (L) marks are aligned. If not, the engine will not operate correctly.
(10)Number the boltholes locations in increments of ten with a C05-003  pen on the forward flange of the CDN assembly. Start at the TVCL with bolthole No. 1 in a CW direction (ALF).
* * * FOR ALL PIP 2
Figure 1011   Installation of the HPT Module Buildup onto the Propulsor Assembly
Subtask 72-00-02-640-049
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
(11)Lubricate the threads and mating faces of the 46 bolts (02-010 , 72-53-00) (SIN 15020) and 46 nuts (34-260) (SIN 15040) with C02-058  graphite. Refer to Figure 1012.
Subtask 72-00-02-430-882
(12)Install the bolts in boltholes 4, 15, 27, 37, 47, 57, 67, 77, 87, 98, 110, 119, and 131 on the extension case (10-080 , 72-30-00) (SIN 080AL) aft flange and the CDN assembly (33-021) (SIN 0010A) or (33-021B) (SIN 0010A) forward flange. Make sure that the boltheads are forward. Hand-tighten the nuts.
(13)Use the 11C3046   camera kit to view the inside diameter of the HPT rotor assembly (34-021) (SIN 15000) and the CDP seal (02-460 , 72-31-00) (SIN 050NC). Make sure that the flanges touch each other and there are no gaps.
Subtask 72-00-02-430-883
(14)Alternative Procedure Available. Remove the 11C3046   camera kit. Refer to Figure 1009 and do as follows:
(a)Turn off the power and disconnect the video monitor (item 8) from the electrical power source.
(b)Disconnect the main cable (item 18).
(c)Disconnect the camera (item 10) and lock ring (item 7) assembly from the guide tube (item 3).
(d)Disconnect the main cable (item 18) from the receptacle (item 16).
(e)Disconnect the main cable (item 17) from the receptacle (item 16).
(f)Remove the 11C3046   camera kit.
Subtask 72-00-02-430-884
(14).A.Alternative Procedure. Remove borescope and the 11C3387   borescope guide from the HPT rotor assembly (34-021) (SIN 15000). Refer to Figure 1009.
Subtask 72-00-02-430-885
(15)Remove the 11C3055   rotor lock from the aft end of the HPT rotor assembly (34-021) (SIN 15000). Refer to TASK 72-50-00-030-801 (72-50-00, DISASSEMBLY 001).
(16)Make sure that no tooling or foreign material is inside the HPT rotor assembly (34-021) (SIN 15000) and the propulsor assembly.
(a)Move the air duct (34-310) (SIN 05002) forward, until the 11C4888   torque wrench can be installed.
Subtask 72-00-02-430-886
(b)Install the 11C4888   torque wrench into the HPT rotor assembly. Refer to Figure 1012 and do as follows:
1Put the sliding gearbox inside the 11C4888   torque wrench until the gearbox can slide.
CAUTION:
INDEX RING ON ADVANCED TORQUE WRENCH MUST BE ALIGNED WITH 1-1 SLOT TO CORRECTLY INSTALL HPT ROTOR ASSEMBLY.
2Put the 11C4888   torque wrench into the HPT rotor assembly. Make sure that the index ring handle is aligned with the 1-1 slot on the HPT rotor assembly.
3Use a C05-003  pen and make a 1-1 mark on the inside of the HPT rotor assembly.
4Connect the sensor cable to the 11C4888   torque wrench.
Subtask 72-00-02-430-887
(17)Install the nuts (34-260) (SIN 15040) on the bolts (02-010 , 72-53-00) (SIN 15020) and (02-020 , 72-53-00) (SIN 15021) in the HPT rotor assembly (34-021) (SIN 15000) and propulsor assembly. The bolts (02-010 , 72-53-00) (SIN 15020), (02-020 , 72-53-00) (SIN 15021) are installed on the aft side of the HPT rotor disk (02-280 , 72-53-00) (SIN 150A1) forward flange with the boltheads aft. The self-locking nuts are installed on the forward side of the CDP seal (02-460 , 72-31-00) (SIN 050NC) aft flange as follows. Refer to Figure 1012 and do as follows:
CAUTION:
DO NOT USE NUTS (34-260) (SIN 15040) THAT HAVE BEEN INSTALLED ON AN ENGINE THAT WAS OPERATED.
(a)If a self-locking nut falls into the propulsor assembly, record that the self-locking nut was found to make sure that all the self-locking nuts were installed.
(b)Install the 46 nuts (34-260) (SIN 15040) on the bolts (02-010 , 72-53-00) (SIN 15020) and (02-020 , 72-53-00) (SIN 15021) and torque according to the instructions on the 11C4888   torque wrench computer.
(c)Torque the self-locking nut to 200 lb in. (22.6 N.m).
(d)Loosen the self-locking nut one full turn.
(e)Tighten the self-locking nut one-half turn and record the run-on torque and make sure the run-on torque is 15-100 lb in. (1.7-11.3 N.m).
(f)If the run-on torque is not in limits, loosen the self-locking nut one full turn and do the run-on torque again. Record the run-on torque. Refer to Figure 1013.
NOTE:
The run-on torque can be done two times. After this, the self-locking nut must be replaced.
(g)Loosen the self-locking nut a minimum of one full turn, and torque the self-locking nut to 70.0 lb in. (7.91 N.m) plus the run-on torque.
(h)Set the 11C4888   torque wrench to read zero degrees.
(i)Turn the self-locking nut 54-58 degrees in a CW direction to tighten and as follows:
1 Make sure that the maximum torque is not more than 850 lb in. (96.0 N.m).
2If the angle or torque is more than the maximum limit, remove and discard the associated bolt and nut.
3Replace with a new bolt and nut.
(j)Disconnect the sensor cable from the 11C4888   torque wrench.
(k)Remove the 11C4888   torque wrench from the HPT rotor assembly.
(18)Do an inspection of CDP bolts and nuts and make sure that the bolt threads extend 2 to 2-1/2 bolt threads above the nut. If not, find the cause and replace the bolt and nut.
Subtask 72-00-02-430-888
(a)Alternative Procedure Available. Use a mirror and a light to do the inspection.
Subtask 72-00-02-430-889
(a).A.Alternative Procedure. Install the 11C3046   camera kit. Refer to Subtask 72-00-02-430-878 (paragraph 3.J.).
1After inspection remove the 11C3046   camera kit. Refer to Subtask 72-00-02-430-883 (paragraph 3.K.(14)).
Subtask 72-00-02-430-890
(a).B.Alternative Procedure. Install 11C3387   borescope guide and use a borescope. Refer to Subtask 72-00-02-430-880 (paragraph 3.J.A.).
1After inspection remove the borescope and the 11C3387   borescope guide from the HPT rotor assembly (34-021) (SIN 15000). Refer to Subtask 72-00-02-430-884 (paragraph 3.K.(14)A.) and Figure 1009.
Subtask 72-00-02-430-891
(19)Remove the 9C1276   bore protector from the stage 10 bore of the stages 6-10 compressor rotor spool (compressor rotor spool) (02-481 , 72-31-00) (SIN 050AR).
Subtask 72-00-02-210-026
(20)Do a visual inspection of the HPC rotor (15-012 , 72-30-00) (SIN 05000) and the HPT rotor (34-021) (SIN 15000) as follows:
(a)Make sure that the bolts (02-020 , 72-53-00) (SIN 15021) are in the correct position on the HPT rotor.
(b)Make sure that there is no tooling or foreign material inside the propulsor assembly.
(c)Check the joint where the HPC rotor (15-012 , 72-30-00) (SIN 05000) aft end connects to the HPT rotor forward end. Make sure that they are aligned correctly.
(d)Do a general visual inspection of the exposed surfaces of HPT rotor stage 1 disk for nicks, dents, and scratches after the removal of tooling. Refer to TASK 72-00-53-200-802 (72-00-53, INSPECTION 001).
Subtask 72-00-02-220-106
(21)Do a borescope inspection of the CDN piston rings (01-220 , 72-41-00) (SIN 122A0) and (01-225 , 72-41-00) (SIN 122A1) as follows:
(a)Use a 3-meter flex scope with a straight view or 90-degree angled tip. If a shorter flex scope is used, the inspection can require the use of two bleed ports to make sure that the piston rings are correctly seated around the full circumference of the piston ring seal channel.
NOTE:
Alternative guide tubes can also be helpful and acceptable to do this task.
(b)Do an inspection of the piston ring seal channel. If evidence is shown that the piston rings (122A0) and (122A1) are dislodged from the groove of the piston ring seal channel (08001), the HPT rotor assembly must be removed from the core and must be installed again until the piston rings are correctly seated in the seal channel.
(c)Do a borescope inspection of the piston ring seal channel as follows:
1Attach the straight-view or 90-degree angled tip to the end of the flex-scope.
2Insert the flex-scope and lead end of the tubing into the 3:00 o'clock transient CDN bleed port.
3Guide the flex-scope through the openings in the diffuser wall and onto the piston ring seal channel. A guide tube can be used to help landing of the scope into the seal channel. Put the flex-scope until the piston ring seal channel is clearly visible.
4Make sure that the ID dimension of the tubing can fit the OD dimension of the flex-scope cable.
5Run the probe around the full circumference of the piston ring seal channel looking and make sure that there are no extrusions of the piston rings. Carefully remove the flex-scope from the tubing.
6If the full circumference of the piston ring seal channel cannot be seen from the 3:00 o'clock transient CDN bleed port, do paragraph 5.L.(21)(c)3 and 5.L.(21)(c)5 with the 9:00 o'clock transient CDN bleed port to make sure that the piston rings are correctly seated, with no extrusions into the seal channel.
* * * FOR ALL PIP 2
Figure 1012   Installation of the Torque Wrench, 11C4888, in HPT Rotor Assembly
* * * FOR ALL PIP 2
Figure 1013   HPT Rotor to Propulsor CDP Seal Bolt Record Sheet
Subtask 72-00-02-480-005
M.Calibrate the inspection probe of the 7C2127   inspection system as follows:
(1)Install the calibration block (item 6) of the 11C3147   runout fixture on the end of the gage arm (item 3) with capscrews (item 12). Refer to Figure 1014.
(2)Install the inspection probe in the split collet (item 17). Adjust the probe to the center of the mechanical movement.
(3)Put the inspection probe electrical lead into the hole in the gage arm (item 3), through the length of the gage arm and out the hole in the aft end of the gage arm.
(4)Connect the inspection probe to the 7C2127   inspection system.
(5)Turn on the 7C2127   inspection system electrical power.
(6)Start the 7C2127   inspection system as follows:
(a)At the SELECT ENGINE SCREEN, select GEnx-1B then NEXT.
(b)At the SELECT A PARAMETER FILE screen, select NX1BCDP.PRM, then OPEN.
(c)At the main page, select GAGE.
Subtask 72-00-02-820-008
(7)Adjust the inspection probe in the split collet (item 17) as near to zero (0.0000) as possible.
(8)Check the calibration response with a 0.001, 0.002, and 0.003 inch (0.025, 0.051, and 0.076 mm) gage between the probe head and the calibration block (item 6). The probe reading must be in 0.0005 inch (0.013 mm). Do the check a second and a third time to make sure that the indication is in the limit.
(9)Remove the capscrews (item 17) and the calibration block (item 6) from the gage arm (item 3).
NOTE:
The 7C2127   inspection system can have more than one probe/data input. If the HPC shaft No. 3 bearing surface is accessible to record runout, it can be recorded for data purposes only. Inspection criteria only applies for the CDP runout surface.
* * * FOR ALL PIP 2
Figure 1014   Calibration of the Inspection System, 7C2127, Inspection Probe
Subtask 72-00-02-430-892
N.Install the 11C3147   runout fixture on the TCF assembly (20A-010 , 72-54-00) (SIN 926A0). Refer to Figure 1015 and do as follows:
(1)Examine the 11C3147   runout fixture for damage, foreign material, and high metal on the mating flange.
(2)Clean the extension nut (item 8) with a clean, lint-free C10-182  cloth.
(3)Locate the two castellations marked 1 on the outer surface on the aft end of the HPT rotor disk (02-280 , 72-53-00) (SIN 150A1) outer surface.
(4)Transfer the number 1-1 to the inside diameter of the HPT rotor disk (02-280 , 72-53-00) (SIN 150A1) with a C05-003  pen .
NOTE:
It can be helpful to make a temporary mark on the outside diameter (OD) to return to that exact same location where the rotation started.
CAUTION:
DO NOT USE TOO MUCH FORCE TO TIGHTEN THE EXTENSION NUT. THE HPT ROTOR DISK CAN BE DAMAGED.
(5)Install the extension nut (item 8) on the HPT rotor disk (02-280 , 72-53-00) (SIN 150A1). Tighten the extension nut. Do not use excessive force to tighten the extension nut.
(6)Turn the knob (item 24) of the 11C3147   runout fixture CW to move the spring loaded cam roller (item 25) outward. Tighten the knob (item 24) to hold in this position and let the cam roller (item 25) to be installed on the extension nut (item 8).
(7)Attach an overhead hoist to the hoist rings (item 16) on the 11C3147   runout fixture.
WARNING:
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR KILL YOU.
(8)Lift the 11C3147   runout fixture and align the TOP VERT mark on the cap (item 4) with the TVCL on the propulsor assembly.
(9)Put the center frame (item 18) on the TCF assembly (20A-010 , 72-54-00) (SIN 926A0) aft flange and attach with nuts (item 14).
* * * FOR ALL PIP 2
Figure 1015   Installation of the Runout Fixture, 11C3147, on the TCF Assembly
Subtask 72-00-02-430-893
CAUTION:
THIS ASSEMBLY IS A CRITICAL PROCEDURE. PROPER USE OF PROTECTIVE TOOLING AND POST ASSEMBLY INSPECTIONS MUST BE COMPLETED. REFER TO THE REQUIREMENTS OF THE ENGINE MANUAL TO MAKE SURE THAT NO DAMAGE HAS BEEN CAUSED BY THE ASSEMBLY PROCEDURE OR TOOLING.
O.Measure the HPT rotor disk (02-280 , 72-53-00) (SIN 150A1) and the CDP seal (02-460 , 72-31-00) (SIN 050NC) for runout as follows:
CAUTION:
THE INSPECTION PROBE OF THE 7C2127 INSPECTION SYSTEM CAN BE DAMAGED EASILY. DO NOT LET THE PROBE TOUCH THE HPT ROTOR DISK OR THE EXTENSION NUT.
(1)Put the gage arm (item 3) of the 11C3147   runout fixture through the cap (item 4). Do not let the inspection system probe touch the HPT rotor disk (02-280 , 72-53-00) (SIN 150A1) and the extension nut (item 8) or the inspection probe can be damaged. Refer to Figure 1015.
(2)Attach the gage arm (item 3) to the cap (item 4) with the mounting screws (item 10). Tighten the setscrew (item 9) and the mounting screws (item 10) to prevent movement of the gage arm (item 3).
(3)Install the encoder wheel of the 7C2127   inspection system on the extension nut (item 8). The encoder wheel will turn with the rotor.
(4)Turn the knob (item 24) CCW to move the spring loaded cam roller (item 25) inward and apply a radial force on the rotor.
(5)Align the inspection probe on the gage arm (item 3) to the CDP seal (02-460 , 72-31-00) (SIN 050NC) and adjust the setscrews (item 9) to read as close as possible to 0.0000 inch. Tighten the mounting screws (item 10).
(6)Make sure that the 11C3133   lock fixture is installed on the TGB (01-010 , 72-25-00) (SIN 03200). Refer to TASK 72-00-02-430-821 (72-00-02, ASSEMBLY 001, CONFIG 02) to install the lock fixture.
(7)Start the 7C2127   inspection system as follows:
(a)At the SELECT ENGINE screen, select GEnx-1B then NEXT.
(b)At the SELECT A PARAMETER FILE screen, select NX1BCDP.PRM, then OPEN.
(c)At the main page, select GAGE.
(8)On the 7C2127   inspection system screen, select MEASURE.
(9)When the screen prompts for a new run, select YES.
(10)Enter the engine serial number, then select OK.
(11)Enter the operator ID, then select OK.
(12)When the screen displays the message POSITION THE ROTOR TO A REFERENCE POSITION, turn the HPT rotor to the number 1 marked on the HPT rotor disk (02-280 , 72-53-00) (SIN 150A1) and select OK or press ENTER to set the zero degrees reference for the measurement. Mark the exact point where the rotor starts. Do not select OK or press ENTER until the measurement is complete.
(13)Put a square drive in the 11C3133   lock fixture and slowly turn the rotor three times CCW (ALF).
(14)Stop the rotor with the inspection probe at the 1-1 mark in the exact same place the rotation started. Select OK on the 7C2127   inspection system screen.
(15)Slowly turn the rotor one revolution CCW (ALF) and stop at the 1-1 mark and select OK. Make sure there is no change in speed when the rotor turns.
(16)Print the plot of the measurement.
(17)If the encoder verification fails, the inspection system will ask you if you want to try again, select YES. Stop at the exact same place you started the measurement.
(18)Turn the rotor CCW (ALF). The inspection system will display the measurement. If the measurement is more than 0.002 inch (0.05 mm) full indicator reading (FIR), check to make sure that the setup is correct and measure again.
(19)If the measurement is less than 0.002 inch (0.05 mm) FIR, the kink check is good.
(20)Deleted.
(21)If the measurement is more than 0.002 inch (0.05 mm) FIR, reseat the HPT rotor disk (02-280 , 72-53-00) (SIN 150A1) on the CDP seal (02-460 , 72-31-00) (SIN 050NC). Refer to Subtask 72-00-02-430-881 (paragraph 3.K.).
CAUTION:
THE INSPECTION PROBE OF THE 7C2127 INSPECTION SYSTEM CAN BE DAMAGED EASILY. DO NOT LET THE PROBE TO TOUCH THE STAGE 1 HPT ROTOR DISK OR THE EXTENSION NUT.
NOTE:
The 7C2127   inspection system can have more than one probe/data input. If the HPC shaft No. 3 bearing surface is accessible to record runout, it can be recorded for data purposes only. Inspection criteria only applies for the CDP runout surface.
(22)If the measurement is correct, select START, then SHUTDOWN, on the 7C2127   inspection system.
(23)Remove the gage arm (item 3) of the 11C3147   runout fixture from the propulsor. Do not let the inspection system probe touch the HPT rotor disk (02-280 , 72-53-00) (SIN 150A1) and the extension nut (item 8) or the inspection probe can be damaged.
(24)Remove the encoder of the 7C2127   inspection system from the center frame (item 18).
(25)Remove the center frame (item 18) of the 11C3147   runout fixture from the TCF assembly (15-130 , 72-54-00) (SIN 925A0) or (15-131 , 72-54-00) (SIN 925A0).
(26)Remove the extension nut (item 8) from the HPT rotor disk (02-280 , 72-53-00) (SIN 150A1).
(27)Remove the 11C3133   lock fixture from the TGB (01-010 , 72-25-00) (SIN 03200).
(28)Record the measurement as COREFIR.
Subtask 72-00-02-220-111
(29)Do a general visual inspection of the exposed surfaces of HPT rotor stage 1 disk for nicks, dents, and scratches after the removal of tooling. Refer to TASK 72-00-53-200-802 (72-00-53, INSPECTION 001).
Subtask 72-00-02-430-894
P.Deleted.
Subtask 72-00-02-430-895
(1)Deleted.
* * * FOR ALL PIP 2
Figure 1016   Bore Protector, 9C1276
Subtask 72-00-02-430-896
Q.Install the brackets on the CDN assembly (33-021) (SIN 0010A) or (33-021B) (SIN 0010A) forward flange and the propulsor assembly aft flange as follows:
(1)Put the boltheads on the forward side of the flange unless instructed differently.
(2)Make sure that the TVCL offset holes are marked on the CDN assembly forward flange. If not, put a mark on the bolthole locations in increments of ten with a C05-003  pen on the forward flange of the CDN assembly. Start at the TVCL with bolthole No. 1 in a CW direction (ALF).
Subtask 72-00-02-640-050
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
(a)Apply C02-058  graphite to the mating surfaces and threads on the bolts (33-060B) (SIN 12021) and (33-070C) (SIN 12022) and bolts (33-050B) (SIN 12020). Do not lubricate the bolts (05-060 , 79-22-30) (SIN 46126) and (01-080 , 75-24-40) (SIN 61B21).
Subtask 72-00-02-430-897
(b)Install the support brackets (05-101 , 79-22-30) (SIN 46110) and (33-290) (SIN 6101K). Refer to Figure 1017 and do as follows:
1Attach the support bracket (33-290) (SIN 6101K) in boltholes No. 2, 3, 4, and 5 on the forward side of the flange with bolts (33-070C) (SIN 12022) and self-locking nuts (33-080) (SIN 12040). Hand tighten the self-locking nuts (33-080) (SIN 12040).
2Attach the support bracket (05-101 , 79-22-30) (SIN 46110) to the support bracket (33-290) (SIN 6101K) with bolts (05-060 , 79-22-30) (SIN 46126).
3Torque the bolts to 106-124 lb in. (12.0-14.0 N.m).
(c)Install the accelerometer cable bracket (33-270) (SIN 34210) in boltholes No. 9, 10, and 11 on the forward side of the flange with bolts (33-070C) (SIN 12022) and self-locking nuts (33-080) (SIN 12040).
(d)Install the support bracket (33-266) (SIN 61A10) in boltholes No. 16, 17, 18, and 19 on the aft side of the flange with bolts (33-070C) (SIN 12022) and self-locking nuts (33-080) (SIN 12040). Hand tighten the self-locking nuts.
(e)Install the support bracket (33-230) (SIN 38410) in boltholes No. 24, 25, and 26 on the forward side of the flange with bolts (33-070C) (SIN 12022) and self-locking nuts (33-080) (SIN 12040). Hand tighten the self-locking nuts.
(f)Install the support bracket (01-040 , 75-42-10) (SIN 61A11) in boltholes No. 28, 29, 30, and 31 on the aft side of the flange with bolts (33-070C) (SIN 12022) and self-locking nuts (33-080) (SIN 12040). Hand tighten the self-locking nuts.
(g)Install the bracket (33-320) (SIN 3411E) in boltholes No. 33, 34, and 35 on the forward side of the flange with bolts (33-070C) (SIN 12022) and self-locking nuts (33-080) (SIN 12040).
(h)Install the heatshield support bracket (40-140) (SIN 29912) in boltholes No. 42, 43, and 44 on the aft side of the flange with bolts (33-070C) (SIN 12022) and self-locking nuts (33-080) (SIN 12040). Hand tighten the self-locking nuts.
(i)Install the heatshield support bracket (40-150) (SIN 29913) in boltholes No. 83 and 84 on the aft side of the flange with bolts (33-070C) (SIN 12022) and self-locking nuts (33-080) (SIN 12040). Hand tighten the self-locking nuts.
Subtask 72-00-02-430-898
(j)Install the FCOC bracket (01-042 , 73-11-20) (SIN 42412) in the boltholes No. 91, 92, 93, and 94 on the forward side of the flange with the bolts (33-070C) (SIN 12022) and self-locking nuts (33-080) (SIN 12040). Hand tighten the self-locking nuts.
1Deleted.
Subtask 72-00-02-430-899
(k)Install the bracket (33-210) (SIN 37113) in boltholes No. 96 and 97 on the forward side of the flange with bolts (33-070C) (SIN 12022) and self-locking nuts (33-080) (SIN 12040). Hand tighten the self-locking nuts.
(l)Install the support brackets (33-190) (SIN 61B10) and (01-150 , 75-24-40) (SIN 61B16) as follows:
1Attach the support bracket (33-190) (SIN 61B10) in boltholes No. 99 and 100 on the forward side of the flange with bolts (33-070C) (SIN 12022) and self-locking nuts (33-080) (SIN 12040). Hand tighten the self-locking nuts.
2Attach the support bracket (01-150 , 75-24-40) (SIN 61B16) to the support bracket (33-190) (SIN 61B10) with bolts (01-101 , 75-24-40) (SIN 61B22).
3Torque the bolts to 106-124 lb in. (12.0-14.0 N.m).
Subtask 72-00-02-430-900
(m)Install the FCOC bracket (01-171 , 73-11-20) (SIN 42410) in boltholes No. 101 and 102 on the forward side of the flange with bolts (33-060B) (SIN 12021) and self-locking nuts (33-080) (SIN 12040). Hand tighten the self-locking nuts.
Subtask 72-00-02-430-901
(n)Install the LPT/ACC supply duct support bracket (LPT/ACC supply duct bracket) (33-170) (SIN 6221D) in boltholes No. 105, 106, 107, 108, and 109 on the aft side of the flange with bolts (33-070C) (SIN 12022) and self-locking nuts (33-080) (SIN 12040). Hand tighten the self-locking nuts.
(o)Install the support brackets (33-130) (SIN 62114) and (33-161) (SIN 34117) as follows:
1Attach the support bracket (33-130) (SIN 62114) in boltholes No. 111, 112, 115, and 116 on the forward side of the flange with bolts (33-070C) (SIN 12022) and self-locking nuts (33-080) (SIN 12040). Hand tighten the self-locking nuts.
2Attach the support bracket (33-161) (SIN 34117) in boltholes No. 113 and 114 on the aft side of the flange with bolts (33-070C) (SIN 12022) and self-locking nuts (33-080) (SIN 12040). Hand tighten the self-locking nuts.
(p)Install the support bracket (33-110) (SIN 34111) in boltholes No. 120 and 121 on the aft side of the flange with bolts (33-070C) (SIN 12022) and self-locking nuts (33-080) (SIN 12040). Hand tighten the self-locking nuts.
(q)Install the bolts (33-050B) (SIN 12020) and self-locking nuts (33-080) (SIN 12040) in boltholes No. 1, 6, 7, 8, 12, 13, 14, 15, 20, 21, 22, 23, 27, 32, 36, 37, 38, 39, 40, 41, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 85, 86, 87, 88, 89, 90, 95, 98, 103, 104, 110, 117, 118, 119, 122, 123, 124, 125, 126, 127, 128, 129, 130, 131, 132, 133, and 134 with the boltheads forward.
Subtask 72-00-02-430-902
(r)Torque the self-locking nuts (33-080) (SIN 12040) as follows:
1Torque a minimum of 14 self-locking nuts (33-080) (SIN 12040) in a criss-cross pattern to 276-324 lb in. (31.4-36.6 N.m) at four equally spaced locations to seat the flanges.
2Make sure that there is no gap between the flanges. Use a 0.001 inch (0.03 mm) gage to check the gap between the flanges.
3Torque the 14 self-locking nuts (33-080) (SIN 12040) in a criss-cross pattern to 368-432 lb in. (41.6-48.8 N.m).
4Torque the 14 self-locking nuts (33-080) (SIN 12040) in a circular pattern to 368-432 lb in. (41.6-48.8 N.m).
(s)If necessary, remove the 7C2015   lift/turn fixture. Refer to TASK 72-50-00-030-801 (72-50-00, DISASSEMBLY 001).
(t)If necessary, remove the 11C3055   rotor lock. Refer to TASK 72-50-00-030-801 (72-50-00, DISASSEMBLY 001).
* * * FOR ALL PIP 2
Figure 1017   (Sheet 1 ) Installation of the Brackets on CDN Assembly and HPC Module Assembly Flange
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Figure 1017   (Sheet 2 ) Installation of the Brackets on CDN Assembly and HPC Module Assembly Flange
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Figure 1017   (Sheet 3 ) Installation of the Brackets on CDN Assembly and HPC Module Assembly Flange
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Figure 1017   (Sheet 4 ) Installation of the Brackets on CDN Assembly and HPC Module Assembly Flange
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Figure 1017   (Sheet 5 ) Installation of the Brackets on CDN Assembly and HPC Module Assembly Flange
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Figure 1017   (Sheet 6 ) Installation of the Brackets on CDN Assembly and HPC Module Assembly Flange
* * * FOR ALL PIP 2
Figure 1017   (Sheet 7 ) Installation of the Brackets on CDN Assembly and HPC Module Assembly Flange
* * * FOR ALL PIP 2
Figure 1017   (Sheet 8 ) Installation of the Brackets on CDN Assembly and HPC Module Assembly Flange
* * * FOR ALL PIP 2
Figure 1017   (Sheet 9 ) Installation of the Brackets on CDN Assembly and HPC Module Assembly Flange
Subtask 72-00-02-430-903
(3)Install the FCOC support bracket (01-180 , 73-11-20) (SIN 42415). Refer to Figure 1017A and do as follows:
(a)Attach the FCOC support bracket (01-180 , 73-11-20) (SIN 42415) to the support bracket (01-061 , 73-11-20) (SIN 42413) and FCOC bracket (01-042 , 73-11-20) (SIN 42412) with two bolts (01-071A , 73-11-20) (SIN 42423), flat wire springs (01-190 , 73-11-20) (SIN 42490), and sliders (01-200 , 73-11-20) (SIN 42491) and (01-210 , 73-11-20) (SIN 42492).
(b)Torque the bolts (01-071A , 73-11-20) (SIN 42423) to 106-124 lb in. (12.0-14.0 N.m).
Subtask 72-00-02-430-904
(4)Connect the support bracket (33-130) (SIN 62114) on the CDN assembly (33-021) (SIN 0010A) or (33-021B) (SIN 0010A) to the LPT ACC bracket (01-210 , 73-11-30) (SIN 62116) with the bolts (33-090) (SIN 62123). Torque the bolts to 106 to 124 lb in. (12.0 to 14.0 Nm). Refer to Figure 1018.
(5)Make sure that the brackets on CDN assembly and propulsor assembly flanges are installed in the correct locations.
* * * FOR ALL PIP 2
Figure 1017A   Installation of the FCOC Support Bracket
* * * FOR ALL PIP 2
Figure 1018   Connection of the CDN Assembly Support Bracket to the LPT ACC Bracket
Subtask 72-00-02-640-051
CAUTION:
THIS ASSEMBLY IS A CRITICAL PROCEDURE. PROPER USE OF PROTECTIVE TOOLING AND POST ASSEMBLY INSPECTIONS MUST BE COMPLETED. REFER TO THE REQUIREMENTS OF THE ENGINE MANUAL TO MAKE SURE THAT NO DAMAGE HAS BEEN CAUSED BY THE ASSEMBLY PROCEDURE OR TOOLING.
R.Install the air duct (34-310) (SIN 05002) in the HPT rotor disk (02-280 , 72-53-00) (SIN 150A1) as follows:
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
(1)Apply C02-058  graphite to the mating surfaces and the threads of the HPT rotor disk. Make sure that the thread roots have lubricant applied.
Subtask 72-00-02-430-905
(2)Install the 11C3055   rotor lock on the aft end of the TCF assembly (15-130 , 72-54-00) (SIN 925A0) or (15-131 , 72-54-00) (SIN 925A0). Refer to Figure 1019 and do as follows:
(3)Install the threaded tube (item 18) as follows:
(a)Put a leverage bar through the 1.00 inch (25.4 mm) diameter holes at the aft end of the threaded tube (item 18).
(b)Thread the forward end of the threaded tube (item 18) into the aft end of the HPT rotor disk (02-280 , 72-53-00) (SIN 150A1).
(c)Remove the leverage bar from threaded tube (item 18).
(4)Attach an approved overhead hoist to the hoist rings (item 11) on the restraint frame (item 19).
WARNING:
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR KILL YOU.
(5)Lift the 11C3055   rotor lock and install on the TCF assembly (15-130 , 72-54-00) (SIN 925A0) or (15-131 , 72-54-00) (SIN 925A0). Align the holes on the restraint ring of the restraint frame (item 19) with the studs on the TCF.
(6)Install the captive nuts (item 8) equally spaced on the studs of the TCF assembly (15-130 , 72-54-00) (SIN 925A0) or (15-131 , 72-54-00) (SIN 925A0).
(7)Torque the captive nuts (item 8) to 10 lb ft (13.56 N.m).
(8)Remove the overhead hoist from the hoist rings (item 11).
(9)Put the anti-torque tube (item 3) in the threaded tube (item 18) until the slots engage in the HPT rotor disk (02-280 , 72-53-00) (SIN 150A1).
(10)Put the adapter pins (item 10) in the anti-torque tube (item 3) and thread into the restraint frame (item 19). There must be a 0.125 inch (3.18 mm) gap between the anti-torque tube (item 3) and the restraint frame (item 19) when the adapter pins (item 10) are installed.
(11)Make sure that a clearance of 0.010 inch (0.25 mm) is between the axial locknut (item 9) and restraint frame (item 19). Use a shim stock or other measurement method.
(12)Tighten the axial locknut (item 9) with a spanner wrench.
(13)Install the two segments of the clamp ring (item 5) to the restraint frame (item 19) with 10 capscrews (item 15).
(14)Torque the capscrews (item 15) to 120 lb in. (13.56 N.m).
* * * FOR ALL PIP 2
Figure 1019   Installation of the Rotor Lock, 11C3055, on the TCF Assembly
Subtask 72-00-02-431-036
(15)Put the 9429M25   torque adapter plate on the 11C3055   rotor lock and attach firmly with the adapter pins (item 10). Refer to Figure 1023.
(16)Install the HPT rotor air duct (34-310) (SIN 05002) in the stage 1 HPT rotor disk (01-280 , 72-53-00) (SIN 150A1) with the 11C3266   air duct installation fixture as follows:
(a)Turn the lower position ring (item 17), in relation to the upper position ring (item 16), until the teeth in the locking ring (item 2) and the torque ring (item 3) are aligned.
(b)Make sure that the ball lock pin (item 19) is in the slot of the UNLOCKED position.
CAUTION:
THE 11C3266   AIR DUCT INSTALLATION FIXTURE MUST BE HELD VERY TIGHTLY TO PREVENT MOVEMENT THAT COULD DAMAGE THE PROPULSOR.
(c)Put the fixture in the center so that the teeth of the fixture is in the teeth of the HPT rotor air duct (34-310) (SIN 05002). The 11C3266   air duct installation fixture must be held very tightly at all times to prevent movement that could damage the propulsor assembly.
NOTE:
An overhead hoist can be used with an approved lift sling to hold the fixture.
(d)Remove the ball lock pin (item 19) and turn the lower position ring (item 17), in relation to the upper position ring (item 16), until the locking ring (item 2) is in the LOCKED position. Make sure that the ball lock pin (item 19) must be in the slot of the LOCKED position.
NOTE:
If contact occurs between the air duct or tooling and the stage 1 disk shaft while lifting the air duct, make sure to inspect the shaft ID surfaces for damage prior to threading the air duct onto the shaft.
(e)Move the HPT rotor air duct (34-310) (SIN 05002) aft with the fixture.
(f)Hold the 11C3266   air duct installation fixture very tightly and move the outer tube (item 6) to align the outer threads on the HPT rotor air duct (34-310) (SIN 05002) with the inner threads of the stage 1 HPT rotor disk (01-280 , 72-53-00) (SIN 150A1) aft shaft.
(g)Manually turn the fixture in a CCW direction to thread the HPT rotor air duct (34-310) (SIN 05002) into the stage 1 HPT rotor disk (01-280 , 72-53-00) (SIN 150A1).
(h)Turn the HPT rotor air duct a minimum of two turns, until it bottoms out in the disk.
(i)Remove the ball lock pin (item 19).
(j)Turn the lower position ring (item 17) to disengage the splines from the HPT rotor air duct.
(k)Remove the 11C3266   air duct installation fixture.
(17)Install the 11C3157   air duct install/remove tool. Refer to Figure 1024 and do as follows:
(a)Clean the tool with a clean, lint-free cloth.
(b)Attach an overhead hoist to the pin on the aft end of the tool.
WARNING:
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR KILL YOU.
(c)Lift the tool and put the forward end in the 9429M25   torque adapter plate and the 11C3055   rotor lock.
(d)Center the tool and engage the splines in the HPT rotor air duct (34-310) (SIN 05002).
NOTE:
（HES）VTINPTO is a print error, change to VTINPTQ. [Run on torque (VTROTQ) + 500]/ torque multiplier ratio. Refer to Case #02145356.
(18)Torque the HPT rotor air duct (34-310) (SIN 05002) as follows:
(a)Use a driver and turn the HPT rotor air duct CCW three complete turns to find the run-on torque.
(b)Make sure that the run-on torque is 0 to 50 lb. ft (0 to 68 Nm). If the run-on torque is more than 50 lb. ft (68 Nm), remove the HPT rotor air duct and find the problem.
(c)Record the run-on torque as VTROTQ. Refer to Figure 1019.
(d)Install the torque multiplier on the 11C3157   air duct install/remove tool, record the serial number of the torque multiplier, and set the torque multiplier to apply torque in the CCW direction.
(e)Calculate the torque to be applied to the torque multiplier and record as VTINPTO. This adds the run-on torque to 500 lb ft (678 Nm).
(f)Record the final torque applied to the torque multiplier as FN_TQ. Refer to Figure 1019.
(g)Record the torque applied to the HPT rotor air duct (34-310) (SIN 05002) as VT_FN_TQ.
Subtask 72-00-02-431-037
(19)Measure dimension K on the HPT rotor air duct (34-310) (SIN 05002) and the stage 1 HPT rotor disk (01-280 , 72-53-00) (SIN 150A1). Refer to Figure 1021 and do as follows:
(a)Get the calculated seating drop for dimension K (calculated) on the record sheet. Refer to Figure 1019.
(b)Measure dimension K at four equally-spaced locations.
(c)Record the minimum and the maximum values for dimension K and calculate the average. Record the average on the record sheet as K_AVG.
(d)Compare the calculated dimension K to the actual dimension K. The tolerance for the seating of the HPT rotor air duct (34-310) (SIN 05002) must be plus or minus 0.003 inch (plus or minus 0.08 mm).
(e)If not in tolerance, continue to torque the HPT rotor air duct (34-310) (SIN 05002) as follows:
1Torque the HPT rotor air duct (34-310) (SIN 05002) in increments of 400 lb. ft (542 Nm). The maximum torque permitted is 1200 lb. ft (1627 Nm).
2If the maximum torque is applied and the HPT rotor air duct (34-310) (SIN 05002) seating drop is not plus or minus 0.003 inch (plus or minus 0.08 mm), remove the HPT rotor air duct from the stage 1 HPT rotor disk (01-280 , 72-53-00) (SIN 150A1). Determine the cause of the error, inspect, and install.
(20)Remove the torque multiplier.
(21)Remove the adapter pins (item 10) of the 11C3055   rotor lock and remove the 9429M25   torque adapter plate.
(22)Remove the 11C3055   rotor lock.
(23)Install the HPT rotor keyed ring (34-320) (SIN 05090) in the groove between the HPT rotor air duct (34-310) (SIN 05002) and the stage 1 HPT rotor disk (01-280 , 72-53-00) (SIN 150A1) with the tabs on the ring forward.
NOTE:
The tabs on the key ring must be installed in a way that they are not adjacent to the missing tab on the air duct.
(24)Make sure that the aft tabs (chamfered end) are in the slots of the rotor disk and that the forward tabs are in the castellations of the HPT rotor air duct. Refer to Figure 1024.
(25)Do a general visual inspection of the exposed surfaces of the HPT rotor stage 1 disk for nicks, dents and scratches after the removal of tooling. Refer to TASK 72-00-53-200-802 (72-00-53, INSPECTION 001).
* * * FOR ALL PIP 2
Figure 1020   Dimensions J, K, and L on the Stage 1 HPT Rotor Disk and the HPT Rotor Air Duct
* * * FOR ALL PIP 2
Figure 1021   HPT Rotor Air Duct Record Sheet
* * * FOR ALL PIP 2
Figure 1022   (Sheet 1 ) Installation of the Air Duct Installation Fixture, 11C3266, on the Rotor Lock, 11C3055
* * * FOR ALL PIP 2
Figure 1022   (Sheet 2 ) Installation of the Air Duct Installation Fixture, 11C3266, on the Rotor Lock, 11C3055
* * * FOR ALL PIP 2
Figure 1023   Installation of the Air Duct Install/Remove Tool, 11C3157
* * * FOR ALL PIP 2
Figure 1024   Installation of the HPT Rotor Keyed Ring in the Stage 1 HPT
Subtask 72-00-02-430-906
S.Install the No. 4 bearing oil radial scoop (No. 4 bearing oil scoop) (35-410) (SIN 01405) and the No. 4 bearing air and oil rotating seal (No. 4 bearing rotating seal) (35-400) (SIN 01408) on the HPT rotor disk (02-280 , 72-53-00) (SIN 150A1) as follows:
(1)Measure dimension OS for the No. 4 bearing oil scoop (35-410) (SIN 01405). Refer to Figure 1025 and do as follows:
(a)Measure the dimension OS at four equally spaced locations.
(b)Record the minimum value and the maximum value for dimension OS on the record sheet. Refer to Figure 1026.
(c)The tolerance for dimension OS is 0.739-0.749 inch (18.77-19.02 mm).
(d)If dimension OS is not in tolerance, replace the No. 4 bearing oil scoop (35-410) (SIN 01405).
(2)Measure dimension AS for the No. 4 bearing rotating seal (35-400) (SIN 01408). Refer to Figure 1027 and do as follows:
(a)Measure the dimension AS at four equally spaced locations.
(b)Record the minimum value and the maximum value for dimension AS on the record sheet. Refer to Figure 1026.
(c)The tolerance for dimension AS is 0.138-0.140 inch (3.51-3.56 mm). If dimension AS is not in tolerance, replace the No. 4 bearing rotating seal (35-400) (SIN 01408).
* * * FOR ALL PIP 2
Figure 1025   Dimension OS for the No. 4 Bearing Oil Scoop Dimension
* * * FOR ALL PIP 2
Figure 1026   Record Sheet for No. 4 Bearing Oil Scoop and Rotating Seal
* * * FOR ALL PIP 2
Figure 1027   Dimension AS for the No. 4 Bearing Rotating Seal
Subtask 72-00-02-370-002
WARNING:
USE THERMAL GLOVES WHEN YOU MOVE OR TOUCH HOT PARTS. HOT PARTS CAN CAUSE INJURY.
(3)Heat the No. 4 bearing oil scoop (35-410) (SIN 01405) and the No. 4 bearing rotating seal (35-400) (SIN 01408) to a temperature range of 300 to 350°F (149 to 177°C). Use a temperature probe to make sure that the No. 4 bearing oil scoop and the No. 4 bearing rotating seal temperature is 300 to 350°F (149 to 177°C).
NOTE:
An induction heater or an oven can be used to heat the parts.
Subtask 72-00-02-500-004
(4)Install No. 4 bearing oil scoop (35-410) (SIN 01405) and the No. 4 bearing rotating seal (35-400) (SIN 01408) on the HPT rotor disk (02-280 , 72-53-00) (SIN 150A1) as follows:
CAUTION:
HIGH METAL MUST BE REMOVED FROM THE RETAINER NUT (ITEM 2) OF THE 11C3067 RETAINER FIXTURE. DAMAGE TO THE SURFACE OF THE NO. 4 BEARING OIL SCOOP (35-410) (SIN 01405) CAN OCCUR IF THERE IS HIGH METAL ON THE RETAINER NUT.
(a)Inspect the mating surface of the retainer nut (item 2) of the 11C3067   retainer fixture for high metal.
WARNING:
USE THERMAL GLOVES WHEN YOU MOVE OR TOUCH HOT PARTS. HOT PARTS CAN CAUSE INJURY.
(b)Put the No. 4 bearing oil scoop (35-410) (SIN 01405) on the HPT rotor disk (02-280 , 72-53-00) (SIN 150A1) with the flat side aft. Refer to Figure 1028.
(c)Put the No. 4 bearing rotating seal (35-400) (SIN 01408) on the HPT rotor disk (02-280 , 72-53-00) (SIN 150A1).
(d)Install the 11C3067   retainer fixture on the No. 4 bearing rotating seal (35-400) (SIN 01408) with the end marked USE FOR RETAINING AFT SEAL on the rotating seal. Turn the fixture CW to install. Refer to Figure 1029.
(e)If the No. 4 bearing oil scoop (35-410) (SIN 01405) and No. 4 bearing rotating seal (35-400) (SIN 01408) are not fully seated, the retainer nut (item 2) has to be removed, inspected, and re-seated.
(f)If the No. 4 bearing oil scoop (35-410) (SIN 01405) and No. 4 bearing rotating seal (35-400) (SIN 01408) are fully seated continue the installation process.
(g)Tighten the 11C3067   retainer fixture to seat the No. 4 bearing oil scoop (35-410) (SIN 01405) and the No. 4 bearing rotating seal (35-400) (SIN 01408). Use a 0.50 inch (12.7 mm) drive in the drive hole to tighten the fixture. Make sure that the oil scoop and rotating seal are seated.
(h)Let the 11C3067   retainer fixture cool down to room temperature.
(i)Remove the 11C3067   retainer fixture from the HPT rotor disk (02-280 , 72-53-00) (SIN 150A1).
(5)Measure the seating dimension ASACT for the No. 4 bearing oil scoop (35-410) (SIN 01405) and the No. 4 bearing rotating seal (35-400) (SIN 01408). Refer to Figure 1030 and do as follows:
(a)Measure the seating dimension ASACT at four equally spaced locations.
(b)Record the minimum value and the maximum value for dimension ASACT on the record sheet. Refer to Figure 1026.
(c)The tolerance for dimension ASACT is 0.7507-0.7977 inch (19.068-20.261 mm).
* * * FOR ALL PIP 2
Figure 1028   Installation of the No. 4 Bearing Oil Scoop and No. 4 Rotating Seal on the HPT Rotor Disk
* * * FOR ALL PIP 2
Figure 1029   Installation of Retainer Fixture, 11C3067, on the No. 4 Bearing Rotating Seal
* * * FOR ALL PIP 2
Figure 1030   Dimension ASACT for Seating the No. 4 Bearing Rotating Seal
Subtask 72-00-02-431-053
T.Install the 11C3055   rotor lock on the aft end of the turbine center frame assembly (35-009) (SIN 92500), (35-010) (SIN 92500), (35-011) (SIN 92500), (35-012) (SIN 92500), or (35-015) (SIN 92500). Refer to Figure 1031 and do as follows:
(1)Install the threaded tube (item 18) as follows:
(a)Put a leverage bar through the 1.00 inch (25.4 mm) diameter holes at the aft end of the threaded tube (item 18).
(b)Thread the forward end of the threaded tube (item 18) into the aft end of the stage 1 HPT rotor disk (01-280 , 72-53-00) (SIN 150A1) or (02-280 , 72-53-00) (SIN 150A1).
(c)Remove the leverage bar from the threaded tube (item 18).
(2)Attach lift strap to the hoist rings (item 11) on the restraint frame (item 19).
(3)Use an overhead hoist to lift the 11C3055   rotor lock and align the holes on the restraint ring of the restraint frame (item 19) with the studs on the turbine frame assembly. Lower the HPT rotor lock to the turbine frame assembly.
(4)Install the captive nuts (item 8) equally-spaced on the studs of the turbine frame assembly.
(5)Torque the captive nuts (item 8) to 10 lb ft (13.56 Nm).
(6)Remove the lift strap and overhead hoist from the hoist rings (item 11).
(7)Install the axial lock nut (item 9) on the aft end of the threaded tube (item 18), but do not tighten.
(8)Put the anti-torque tube (item 3) in the threaded tube (item 18) and engage the slots in the stage 1 HPT rotor disk (01-280 , 72-53-00) (SIN 150A1) or (02-280 , 72-53-00) (SIN 150A1).
(9)Put the adapter pins (item 10) in the anti-torque tube (item 3) and thread into the restraint frame (item 19). There must be a 0.125 inch (3.18 mm) gap between the anti-torque tube (item 3) and the restraint frame (item 19) when the adapter pins (item 10) are installed.
(10)Tighten the axial locknut (item 9) with a spanner wrench.
(11)Install the two segments of the clamp ring (item 5) to the restraint frame (item 19) with 10 capscrews (item 15).
(12)Torque the capscrews (item 15) to 120 lb in (13.56 Nm).
* * * FOR ALL PIP 2
Figure 1031   HPT Rotor Lock
Subtask 72-00-02-430-907
U.Alternative Procedure Available. Turn the propulsor assembly to the horizontal position in the 9481M84   assembly stand. Refer to Figure 1032 and do as follows:
CAUTION:
UNLESS THE 9481M84 ASSEMBLY STAND MUST BE MOVED, THE FLOOR LOCKS MUST TOUCH THE FLOOR AT ALL TIMES. THE FLOOR LOCKS KEEP THE 9481M84   ASSEMBLY STAND STABLE AND PREVENT DAMAGE TO THE CASTERS.
(1)If the 9481M84   assembly stand was moved, lower the floor locks (item 4) until they touch the floor. Make sure that the assembly stand does not move.
(2)Make sure that all of the bolts that attach the 11C3197   bracket set to the fan hub module (25-011) (SIN 00102) or (25-012) (SIN 00102) are installed tightly. Refer to Figure 1001.
(3)Attach an overhead hoist to the 7C2015   lift/turn fixture.
WARNING:
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR KILL YOU.
(4)Lift and attach the 7C2015   lift/turn fixture to the 11C3025   strongback on the aft end of the propulsor assembly.
CAUTION:
THE TOOLING MUST BE ATTACHED CORRECTLY TO THE PROPULSOR ASSEMBLY TO PREVENT DAMAGE TO THE PROPULSOR ASSEMBLY WHEN IT IS TURNED TO THE HORIZONTAL POSITION.
(5)Apply lift pressure to the 7C2015   lift/turn fixture.
CAUTION:
DO NOT REMOVE THE HOIST UNTIL THE ASSEMBLY STAND SUPPORTS ARE ATTACHED SAFELY IN PLACE.
(6)Move the support (item 5) of the 9481M84   assembly stand to the location where the aft end of the propulsor will be turned to the horizontal position. Do not torque the capscrews (item 29) that attach the support (item 5) to the frame until the alignment to the 11C3025   strongback is done.
(7)Remove the ball-lock pins (items 12 and 17) of the 9481M84   assembly stand that attach the 11C3197   bracket set to the propulsor assembly.
(8)Carefully turn the propulsor assembly to the horizontal position.
(9)Attach the support (item 5) of the 9481M84   assembly stand to the 11C3025   strongback with the ball-lock pin (item 11).
(10)Secure the propulsor assembly to the 9481M84   assembly stand in the horizontal position.
* * * FOR ALL PIP 2
Figure 1032   (Sheet 1 ) Rotation of the Propulsor Assembly to the Horizontal Position
* * * FOR ALL PIP 2
Figure 1032   (Sheet 2 ) Rotation of the Propulsor Assembly to the Horizontal Position
Subtask 72-00-02-430-908
U.A.Alternative Procedure. Turn the propulsor assembly to the horizontal position from the 11C4582   core module build-up fixture into the pedestals. Refer to Figure 1032A and do as follows:
WARNING:
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR KILL YOU.
CAUTION:
THE TOOLING MUST BE ATTACHED CORRECTLY TO THE PROPULSOR ASSEMBLY TO PREVENT DAMAGE TO THE PROPULSOR ASSEMBLY WHEN IT IS TURNED TO THE HORIZONTAL POSITION.
(1)Lift and attach the 7C2015   lift/turn fixture to the 11C3025   strongback on the aft end of the propulsor assembly.
(2)Attach an overhead hoist to the 7C2015   lift/turn fixture.
(3)Loosen the 12 screws (item 3) and washers (item 4) that attach the 11C4582   core module build-up fixture to the fan hub module.
(4)Apply lift pressure to the 7C2015   lift/turn fixture.
WARNING:
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR KILL YOU.
(5)Lift the propulsor free from the 11C4582   core module build-up fixture.
(6)Attach the 11C3039   bracket set to the fan hub frame (FHF) (10-401 , 72-25-00) (SIN 84000) or (10-402 , 72-25-00) (SIN 84000).
(7)Install the 11C3057   fan frame lift/turn fixture and attach an overhead hoist to it.
WARNING:
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR KILL YOU.
(8)Lift the 11C3057   fan frame lift/turn fixture to turn the propulsor assembly.
(9)Lower the 11C3025   strongback .
(10)Lower the propulsor assembly into the 11C3281   pedestals.
* * * FOR ALL PIP 2
Figure 1032A   (Sheet 1 ) Rotation of the Propulsor Assembly to the Horizontal Position
* * * FOR ALL PIP 2
Figure 1032A   (Sheet 2 ) Rotation of the Propulsor Assembly to the Horizontal Position
Subtask 72-00-02-430-909
V.Install the propulsor assembly on the 11C3044   engine module adapter assembly. The 11C3044   engine module adapter assembly includes the 9429M43   fan frame overhead adapter, 9429M45   K-flange overhead adapter, 9429M46   TCF overhead adapter, and 9429M48   bridge beam adapter. Refer to Figure 1033.
(1)Install the 9429M48   bridge beam adapter to the left/right track of the customer overhead rail system as follows:
(a)Put the clevis (item 3) in the hole of the beam (item 2).
(b)Put the retaining ring (item 4) around the groove in the clevis (item 3).
(c)Align the holes of the clevis (item 3) with the customer overhead rail system and secure with shoulder screws (item 5) and nuts (item 6).
(2)Install the 9429M43   fan frame overhead adapter on the 9429M48   bridge beam adapter as follows:
(a)Put the hangers (item 2) of the 9429M43   fan frame overhead adapter on the 9429M48   bridge beam adapter with the open end outward.
(b)Attach the retainers (item 3) with the capscrews (item 5). Do not tighten the capscrew (item 5) until the customer overhead rail system is aligned to the propulsor assembly.
(c)Attach the turnbuckles (item 4) to the retainers (item 2) with the turnbuckle screw, nut, and cotter pin.
(3)Install the 9429M46   TCF overhead adapter as follows:
(a)Put the hanger (item 2) on the customer overhead rail system with the open end of the hook outward.
(b)Attach the retainer (item 4) with the shoulder screw (item 7). Do not tighten the shoulder screw (item 7) until the customer overhead rail system is aligned to the propulsor assembly.
(c)Attach the turnbuckles (item 5) to the hanger (item 2) with the screw, nut, and cotter pin on the turnbuckle (item 5).
(d)Attach the shackles (item 6) to the turnbuckles (item 5) with the bolt, nut, and cotter pin on the shackle (item 6).
(4)Install the 9429M45   K-flange overhead adapter as follows:
(a)Thread the RH threaded rod (item 3) and the LH threaded rod (item 4) into the turnbuckle (item 5) and secure with pins (item 9).
(b)Attach the right threaded rods (item 3) to the customer overhead rail system on the left/right side with the shoulder screws (item 7) and the nut (item 8).
(c)Attach the right (ALF) bracket (item 2) to the aft flange of the combustor case (01-230 , 72-41-00) (SIN 12001) or (01-230A , 72-41-00) (SIN 12001) with capscrews (item 11) in the boltholes No. 8, 9, 10, 11, 12, 13, and 14 from the TVCL on the propulsor assembly.
(d)Attach the left (ALF) bracket (item 2) to the forward flange of the extension case (10-080 , 72-30-00) (SIN 080AL) with capscrews (item 11) in the boltholes No. 122, 123, 124, 125, 126, 127, and 128 from TVCL on the propulsor assembly.
(e)Torque the capscrews (item 11) to 200 lb in (22.6 N.m).
(5)Install the 11C3057   fan frame lift/turn fixture on the FHF (10-401 , 72-25-00) (SIN 84000) or (10-402 , 72-25-00) (SIN 84000) forward and aft flanges as follows:
(a)Align the 11C3057   fan frame lift/turn fixture the TVCL of the propulsor assembly.
(b)Put the bracket (item 7) on the forward side of the FHF (10-401 , 72-25-00) (SIN 84000) or (10-402 , 72-25-00) (SIN 84000) flanges.
(c)Attach the bracket (item 7) with capscrews (item 6) and tighten.
Subtask 72-00-02-430-910
(5).A.Attach the 11C4480   FHF brackets to the FHF (10-401 , 72-25-00) (SIN 84000) or (10-402 , 72-25-00) (SIN 84000). Refer to Figure 1033 and do as follows:
(a)Remove the flange cap screw (item 4) from the storage locations on the brackets (items 2 and 3).
(b)Put the left bracket (item 3) on FHF flange at the 11:00 o’clock position, from the aft end of the FHF looking forward, and attach the left bracket (item 3) with five flange cap screws (item 4).
(c)Tighten the flange cap screws (item 4) to secure the left bracket (item 3).
(d)Put the right bracket (item 2) on FHF flange at the 1 o’clock position, from the aft end of the FHF looking forward, and attach the right bracket (item 2) with five flange cap screws (item 4).
(e)Tighten the flange cap screws (item 4) to secure the right bracket (item 2).
Subtask 72-00-02-430-911
(6)Install the 7C2015   lift/turn fixture to the aft end of the propulsor as follows:
(a)Attach an overhead hoist to the 7C2015   lift/turn fixture.
(b)Put the 7C2015   lift/turn fixture on the 11C3025   strongback and attach with pins (item 3) at two locations.
* * * FOR ALL PIP 2
Figure 1033   (Sheet 1 ) Installation of the Propulsor Assembly, 11C3044, to the Customer Overhead Rail System
* * * FOR ALL PIP 2
Figure 1033   (Sheet 2 ) Installation of the Propulsor Assembly, 11C3044, to the Customer Overhead Rail System
* * * FOR ALL PIP 2
Figure 1033   (Sheet 3 ) Installation of the Propulsor Assembly, 11C3044, to the Customer Overhead Rail System
* * * FOR ALL PIP 2
Figure 1033   (Sheet 4 ) Installation of the Propulsor Assembly, 11C3044, to the Customer Overhead Rail System
* * * FOR ALL PIP 2
Figure 1033   (Sheet 5 ) Installation of the Propulsor Assembly, 11C3044, to the Customer Overhead Rail System
* * * FOR ALL PIP 2
Figure 1033   (Sheet 6 ) Installation of the Propulsor Assembly, 11C3044, to the Customer Overhead Rail System
* * * FOR ALL PIP 2
Figure 1033   (Sheet 7 ) Installation of the Propulsor Assembly, 11C3044, to the Customer Overhead Rail System
Subtask 72-00-02-430-912
CAUTION:
DO NOT REPLACE PARTS THAT ARE NOT AN EQUIVALENT PART. NO SUBSTITUTIONS ARE PERMITTED. DAMAGE TO THE PROPULSOR CAN OCCUR.
(7)Check the 11C3044   engine module adapter assembly and the 9481M84   assembly stand as follows:
CAUTION:
UNLESS THE 9481M84   ASSEMBLY STAND MUST BE MOVED, THE FLOOR LOCKS MUST TOUCH THE FLOOR AT ALL TIMES. THE FLOOR LOCKS KEEP THE 9481M84   ASSEMBLY STAND STABLE AND PREVENT DAMAGE TO THE CASTERS.
(a)Make sure the levelizing jacks (item 34) of the 9481M84   assembly stand touch the floor.
(b)Make sure the 9481M84   assembly stand stand is level.
(c)Check the 11C3044   engine module adapter assembly turnbuckles and shackles for bending, cracks, hole elongation, and missing parts.
(d)Check the 11C3044   engine module adapter assembly turnbuckles to make sure that there are threads visible in the turnbuckle.
(e)Check all hook attachments for cracks, bending, and thread or tube elongation.
(f)Make sure that the hook swivel locks are not missing.
(g)Make sure that the pin joints to spreader bar and shoulder links have a shoulder bolt installed.
Subtask 72-00-02-430-913
(8)Install the propulsor assembly to the overhead support assembly. Refer to Figure 1033 and do as follows:
(a)Find and lower the overhead support assembly on the 9481M84   assembly stand.
(b)Attach the turnbuckles (item 4) of the 9429M43   fan frame overhead adapter to the 11C3057   fan frame lift/turn fixture or 11C4480   FHF brackets with the screw, nut, and cotter pin of the turnbuckle.
(c)Attach the turnbuckle (item 4) of the 9429M45   K-flange overhead adapter to the brackets (item 2) with the ball-lock pins (item 6). The brackets (item 2) are installed on the extension case (10-080 , 72-30-00) (SIN 080AL) and the combustor case (01-230 , 72-41-00) (SIN 12001) or (01-230A , 72-41-00) (SIN 12001). Adjust the turnbuckles (item 4) to align the pin holes.
(d)Attach the shackles (item 6) of the 9429M46   TCF overhead adapter to the 7C2015   lift/turn fixture with the bolt, nut, and cotter pin of the shackle.
Subtask 72-00-02-430-914
WARNING:
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR KILL YOU.
(9)If necessary, remove the 7C2015   lift/turn fixture. Refer to TASK 72-50-00-030-801 (72-50-00, DISASSEMBLY 001).
CAUTION:
THE ALIGNMENT PINS AT 12:00 AND 6:00 O'CLOCK POSITIONS ON THE 11C3025   STRONGBACK CAN CAUSE DAMAGE TO THE STAGE 1 LPT NOZZLES LOCATED ON THE AFT SIDE OF TCF.
(10)If necessary, remove the 11C3025   strongback . Refer to TASK 72-50-00-030-801 (72-50-00, DISASSEMBLY 001).
Subtask 72-00-02-220-104
W.Install the No. 3 bearing locknut (locknut) (20-080) (SIN 030AD) on the forward compressor rotor shaft (02-780 , 72-31-00) (SIN 050B5) as follows:
(1)Measure the locknut (20-080) (SIN 030AD) dimension 030ADTHK. Refer to Figure 1034 and do as follows:
(a)Measure the dimension 030ADTHK at four equally spaced locations.
(b)Record the minimum value and the maximum value for dimension 030ADTHK on the record sheet. Refer to Figure 1035.
(c)The tolerance for dimension 030ADTHK is 1.9315-1.9395 inches (49.062-49.262 mm). If dimension 030ADTHK is not in tolerance, replace the locknut (20-080) (SIN 030AD).
Subtask 72-00-02-640-052
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THESE PRODUCTS.
(2)Apply C02-019  engine oil or C02-023  engine oil to the mating surfaces and threads on the locknut (20-080) (SIN 030AD).
Subtask 72-00-02-430-915
CAUTION:
THE LOCKNUT AND THE FORWARD COMPRESSOR ROTOR SHAFT CAN BE DAMAGED IF THE LOCKNUT IS CROSS-THREADED.
(3)Put the locknut (20-080) (SIN 030AD) on the forward compressor rotor shaft (02-780 , 72-31-00) (SIN 050B5). Make sure not to cross-thread the locknut. Hand tighten the locknut.
* * * FOR ALL PIP 2
Figure 1034   Dimension 030ADTHK for the Locknut
* * * FOR ALL PIP 2
Figure 1035   Record Sheet for the Installation of the Locknut
Subtask 72-00-02-430-916
(4)Deleted.
Subtask 72-00-02-430-917
(5)Install the 11C3053   torque adapter on the FHF assembly (01-491 , 72-26-00) (SIN 840A0) or (01-492 , 72-26-00) (SIN 840A0). Refer to Figure 1036 and do as follows:
(a)Clean the 11C3053   torque adapter with a clean, lint-free C10-182  cloth.
(b)Put the guide tube (item 4) in the bore of the forward compressor rotor shaft (02-780 , 72-31-00) (SIN 050B5).
(c)Attach the tube guide (item 2) to the FHF assembly (01-491 , 72-26-00) (SIN 840A0) or (01-492 , 72-26-00) (SIN 840A0) with the nuts (item 6).
(d)Put the torque tube (item 3) in the tube guide (item 2) and side forward into the guide tube (item 4).
(e)Move the torque tube (item 3) aft and engage with the castellations on the locknut (20-080) (SIN 030AD).
(6)Install the torque multiplier on the torque tube (item 3). Set the torque multiplier to apply torque.
* * * FOR ALL PIP 2
Figure 1036   (Sheet 1 ) Installation of the Torque Adapter, 11C3053, on the FHF Assembly
* * * FOR ALL PIP 2
Figure 1036   (Sheet 2 ) Installation of the Torque Adapter, 11C3053, on the FHF Assembly
Subtask 72-00-02-430-918
(7)Torque the locknut (20-080) (SIN 030AD) on the forward compressor rotor shaft (02-780 , 72-31-00) (SIN 050B5). Refer to Figure 1036 and do as follows:
(a)Torque the locknut to 1300 lb ft (1763 N.m).
(b)Set the torque multiplier to break, and decrease the torque value to zero.
(c)Set the torque multiplier to apply torque, and torque the locknut to 650 lb ft (881 N.m).
CAUTION:
TORQUE MUST NOT BE MORE THAN 900 LB FT (1220 N.M). DAMAGE TO LOCKNUT AND THE FORWARD COMPRESSOR ROTOR SHAFT CAN OCCUR.
(d)Check the slot alignment of the locknut, forward compressor rotor shaft (02-780 , 72-31-00) (SIN 050B5), and keyed ring (20-470) (SIN 030AL) or (20-471) (SIN 030AL). If the inner/outer keys are not aligned correctly, continue to apply torque to the locknut until the keys on the keyed ring are aligned correctly. The maximum torque is 900 lb ft (1220 N.m).
(e)Record the final torque applied to the locknut on the record sheet. Refer to Figure 1035.
(f)Remove the torque multiplier, torque tube (item 3) and guide tube (item 4) of the 11C3053   torque adapter.
Subtask 72-00-02-220-105
(8)Calculate the locknut (20-080) (SIN 030AD) seating dimension 030ADCAL (030ADTHK-Y). Refer to Figure 1035.
(9)Measure and calculate the seating drop of the locknut (20-080) (SIN 030AD). Refer to Figure 1037 and do as follows:
(a)Measure the dimension 030ADACT at four equally spaced locations from the forward face of the locknut (20-080) (SIN 030AD) to the forward end of the compressor rotor shaft (02-780 , 72-31-00) (SIN 050B5).
(b)Record the average value for dimension 030ADACT on the record sheet. Refer to Figure 1035.
(c)The tolerance for dimension 030ADACT is 0.0795-0.1175 inch (2.019-2.984 mm).
(d)Calculate the seating drop tolerance for the locknut (20-080) (SIN 030AD) (030ADACT - 030ADCAL). The tolerance for the seating drop difference is -0.001 to -0.009 inch (-0.03 to -0.23 mm).
(10)If the seating dimension is not in tolerance, remove the locknut (20-080) (SIN 030AD) and reinstall. Refer to Subtask 72-00-02-220-104 (paragraph 3.U.(1)) thru Subtask 72-00-02-430-918 (paragraph 3.U.(7)).
Subtask 72-00-02-430-919
(11)Install the keyed ring (20-470) (SIN 030AL) or (20-471) (SIN 030AL) and the retaining ring (20-460) (SIN 030V1). Refer to Figure 1037 and do as follows:
(a)Install the keyed ring in the locknut.
NOTE:
The keyed ring has two inner keys and two outer keys. The outer keys align with the slots on the locknut. The inner keys align with the slots on the forward compressor rotor shaft.
(b)Install the retainer ring (20-460) (SIN 030V1) in the slot of the locknut.
(c)Make sure that the retainer ring (20-460) (SIN 030V1) is seated.
* * * FOR ALL PIP 2
Figure 1037   (Sheet 1 ) Dimension 030ADACT for the Locknut
* * * FOR ALL PIP 2
Figure 1037   (Sheet 2 ) Dimension 030ADACT for the Locknut
* * * FOR ALL PIP 2
Figure 1037   (Sheet 3 ) Dimension 030ADACT for the Locknut
Subtask 72-00-02-430-920
(12)Put the 9429M25   torque adapter plate on the 11C3055   rotor lock and secure with adapter pins (item 11). Refer to Figure 1038.
(13)Install the air duct (34-310) (SIN 05002) in the HPT rotor disk (02-280 , 72-53-00) (SIN 150A1) with the 11C3266   air duct installation fixture as follows:
(a)Turn the lower position ring (item 17), in relation to the upper position ring (item 16), until the teeth in the locking ring (item 2) and the torque ring (item 3) are aligned. The ball lock pin (item 19) must be in the slot of the UNLOCKED position.
CAUTION:
THE 11C3266 AIR DUCT INSTALLATION FIXTURE MUST BE HELD VERY TIGHTLY TO PREVENT MOVEMENT THAT COULD DAMAGE THE PROPULSOR.
(b)Put the fixture in the center for the teeth of the fixture will be in the teeth of the air duct (34-310) (SIN 05002). You must hold the 11C3266   air duct installation fixture very tightly at all times to prevent movement that could damage the propulsor assembly.
NOTE:
You can use an overhead hoist with an approved lift sling to hold the fixture.
(c)Remove the ball lock pin (item 19) and turn the lower position ring (item 17), in relation to the upper position ring (item 16), until the locking ring (item 2) is in the locked position. The ball lock pin (item 19) must be in the slot of the LOCKED position.
(d)Move the air duct (34-310) (SIN 05002) aft with the 11C3266   air duct installation fixture.
(e)Hold the 11C3266   air duct installation fixture very tightly and move the outer tube (item 6) to align the outer threads on the air duct with the inner threads of the HPT rotor disk (02-280 , 72-53-00) (SIN 150A1) aft shaft.
(f)Turn the 11C3266   air duct installation fixture in a CCW direction to thread the air duct (34-310) (SIN 05002) into the HPT rotor disk (02-280 , 72-53-00) (SIN 150A1). Turn the air duct until it bottoms out in the disk. The air duct must be turned a minimum of two turns.
(g)Remove the ball lock pin (item 19).
(h)Turn the lower position ring (item 17) to disengage the splines from the air duct.
(i)Remove the 11C3266   air duct installation fixture.
(14)Install the 11C3157   air duct install/remove tool. Refer to Figure 1039 and do as follows:
(a)Clean the tool with a clean, lint-free C10-182   cloth.
WARNING:
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR KILL YOU.
(b)Use an overhead hoist with an approved lift strap attached to the 9/16 inch (14 mm) pin on the aft end of the tool to help when the tool is lifted.
(c)Lift the 11C3157   air duct install/remove tool and put the forward end in the 9429M25   torque adapter plate and the 11C3055   rotor lock.
(d)Center the 11C3157   air duct install/remove tool and engage the splines in the air duct (34-310) (SIN 05002).
(15)Torque the air duct (34-310) (SIN 05002) as follows:
(a)Install the torque multiplier on the 11C3157   air duct install/remove tool. Record the serial number of the torque multiplier. Set the torque multiplier to apply torque in the CCW direction.
(b)Make sure that the air duct (34-310) (SIN 05002) is seated against HPT shaft.
(c)Install a torque wrench on the torque multiplier and turn the air duct CCW three complete turns to find the run-on torque.
(d)The run-on torque must be 0-50 lb ft (0-67.8 N.m). If the run-on torque is more than 50 lb ft (67.8 N.m), disassemble and find the problem.
(e)Record the run-on torque as VTROTQ. Refer to Figure 1040.
(f)Calculate the torque to be applied to the torque multiplier and record as VTINPTO. This adds the run-on torque to 500 lb ft (678 N.m).
(g)Torque the air duct (34-310) (SIN 05002).
(h)Record the final torque applied to the torque multiplier as FN_TQ.
(i)Record the torque applied to the air duct (34-310) (SIN 05002) as VT_FN_TQ.
(16)Remove the torque multiplier.
(17)Remove the adapter pins (item 10) of the 11C3055   rotor lock to remove the 9429M25   torque adapter plate.
(18)Remove the 11C3055   rotor lock. Refer to TASK 72-50-00-030-801 (72-50-00, DISASSEMBLY 001).
* * * FOR ALL PIP 2
Figure 1038   (Sheet 1 ) Installation of the Air Duct Installation Fixture, 11C3266, on the Rotor Lock, 11C3055
* * * FOR ALL PIP 2
Figure 1038   (Sheet 2 ) Installation of the Air Duct Installation Fixture, 11C3266, on the Rotor Lock, 11C3055
* * * FOR ALL PIP 2
Figure 1039   Installation of the Air Duct Install/Remove Tool, 11C3157
* * * FOR ALL PIP 2
Figure 1040   Record Sheet for the Air Duct
Subtask 72-00-02-430-921
(19)Measure dimension K on the air duct (34-310) (SIN 05002) and the HPT rotor disk (02-280 , 72-53-00) (SIN 150A1). Refer to Figure 1041 and do as follows:
(a)Get the calculated seating drop for dimension K and record on the record sheet. Refer to Figure 1040.
(b)Measure dimension K at four equally spaced locations.
(c)Record the minimum and the maximum values for dimension K and calculate the average. Record the average on the record sheet as K_AVG.
(d)The tolerance for the seating of the air duct must be plus or minus 0.003 inch (0.08 mm).
(e)If not in tolerance, continue to torque the air duct as follows:
1Torque the air duct (34-310) (SIN 05002) in increments of 400 ft lb (4800 N.m). The maximum torque permitted is 1200 lb ft (16272 N.m). Refer to TASK 72-00-02-430-821 (72-00-02, ASSEMBLY 001, CONFIG 02).
2If the maximum torqued is applied and the air duct seating drop is not plus or minus 0.003 inch (0.08 mm), remove the air duct from the HPT rotor disk to determine the cause of the error, inspect, and install.
(20)Install the HPT rotor keyed ring (34-320) (SIN 05090) in the groove between the air duct (34-310) (SIN 05002) and the HPT rotor disk (02-280 , 72-53-00) (SIN 150A1) with the tabs on the ring forward. Make sure that the aft tabs (chamfered end) are in the slots of the rotor disk and make sure that the forward tabs are in the castellations of the air duct. Refer to Figure 1042.
* * * FOR ALL PIP 2
Figure 1041   Dimension K on the HPT Rotor Disk and the Air Duct
* * * FOR ALL PIP 2
Figure 1042   Installation of the HPT Rotor Keyed Ring in the HPT Rotor Disk
Subtask 72-00-02-430-922
X.Continue to assemble the propulsor assembly. Refer to TASK 72-00-02-430-814 (72-00-02, ASSEMBLY 003).